Method and apparatus for producing multi-compartment packages

ABSTRACT

An improved method and apparatus for making a multi-compartment package on a form, fill, and seal machine. Two pairs of heat sealing jaws are provided which produce seals having different sealing strengths.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of co-pending U.S. patentapplication Ser. No. 13/914,204, entitled “Method and Apparatus forProducing Multi-Compartment Packages,” filed Jun. 10, 2013, thetechnical disclosure of which is hereby incorporated by reference in itsentirety.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a package made from a modified form,fill, and seal packaging machine, and the apparatus and method formaking same, that provides for a single piece construction of amulti-compartment package. In particular, the invention provides aflexible film package that has two or more compartments, with eachcompartment separated by a rupturable seal.

2. Description of Related Art

Vertical and horizontal form, fill, and seal packaging machines arecommonly used in the snack food industry for forming, filling, andsealing bags of chips and other like products. At present, no knownform, fill, and seal machine is capable of producing multi-compartmentpackages from a single tube of packaging film.

SUMMARY OF THE INVENTION

The proposed invention involves producing a multi-compartment packageusing a vertical form, fill, and seal machine modified with a secondpair of heat seal bars. A method for making a multi-compartment packagecomprises the steps of: forming a first end seal with a first pair ofsealing jaws to form an open ended tube of packaging film; filling saidopen ended tube with a predetermined amount of a first product; forminga middle seal on said open ended tube with a second pair of sealing jawsto form a first compartment between said first end seal and said middleseal containing said first product; filling said open ended tube with apredetermined amount of a second product; pulling said open ended tubedownward; forming a second end seal with said first pair of sealing jawsto seal said open ended tube and form a multi-compartment package havinga second compartment between said second end seal and said middle sealcontaining said second product. The method may further comprise cuttingsaid multi-compartment package away from said open ended tube.

Another embodiment of the invention involves producing amulti-compartment package using a horizontal form, fill, and sealmachine with a modified seal bar and filler arrangement. A method formaking a multi-compartment package comprises the steps of: forming afolded packaging film web from an unwinding roll of packaging film;forming a first vertical end seal on said folded packaging film web;forming a vertical middle seal on said folded packaging film web;forming a second vertical end seal on said folded packaging film web,wherein said vertical middle seal is located between said first verticalend seal and said second vertical end seal; cutting said foldedpackaging film web at said first vertical end seal and said secondvertical end seal to produce a multi-compartment, vertically orientedpouch having a top, as well as a first compartment and a secondcompartment separated by said vertical middle seal, wherein each saidcompartment comprises an open mouth at the top of the pouch; optionallyopening said open mouths; filling each said compartment through its openmouth with a predetermined amount of a first product or a secondproduct; forming a horizontal top seal on said pouch which closes saidopen mouths and forms a sealed first compartment between said firstvertical end seal and said vertical middle seal, and a second sealedcompartment between said second vertical end seal and said verticalmiddle seal.

In a preferred embodiment, the first compartment is filled with a firstproduct and the second compartment is filled with a second product whichis different from the first product. In one embodiment, the firstproduct comprises snack chips and the second product comprises salt. Inanother embodiment, the first product comprises a food product with amoisture content of less than 4% by weight, and the second productcomprises a food product with a moisture content of greater than 5% byweight. In still another embodiment, the first product comprises a foodproduct with a first seasoning, and the second product comprises a foodproduct with a second seasoning which is different than the firstseasoning.

In one embodiment, the middle vertical seal is thinner than the firstvertical end seal and the second vertical end seal. In anotherembodiment, the middle vertical seal comprises a first seal strength,the first vertical end seal comprises a second seal strength, the secondvertical end seal comprises a third seal strength, and the horizontaltop seal comprises a fourth seal strength, wherein the first sealstrength is lower than the second seal strength, the third seal strengthand the fourth seal strength

In one embodiment, the first product comprises snack chips and thesecond product comprises salt. In another embodiment, the first productcomprises a food product with a moisture content of less than 4% byweight, and the second product comprises a food product with a moisturecontent of greater than 5% by weight. In still another embodiment, thefirst product comprises a food product with a first seasoning, and thesecond product comprises a food product with a second seasoning which isdifferent than said first seasoning.

In one embodiment, the middle seal is thinner than the first end sealand the second end seal. In another embodiment, the middle sealcomprises a first seal strength, the first end seal comprises a secondseal strength, and the second end seal comprises a third seal strength,wherein the first seal strength is lower than the second seal strengthand the third seal strength.

Another embodiment of the invention is a vertical form, fill, and sealmachine comprising a product delivery tube, a first pair of sealingjaws, and a second pair of sealing jaws between the first pair ofsealing jaws and a discharge end of the product delivery tube. Thevertical form, fill, and seal machine may further comprise a first feedtube configured to deliver a first product to said product deliverytube, and a second feed tube configured to deliver a second product tosaid product delivery tube.

Another embodiment of the invention is a horizontal form, fill, and sealmachine comprising a forming neck configured to convert an unwindingroll of packaging film into a folded packaging film web; at least onepair of end heat seal bars configured to form a first vertical end sealand a second vertical end seal on said folded packaging film web; a pairof middle heat seal bars configured to form a vertical middle sealbetween said first vertical end seal and said second vertical end seal;a cutter configured to cut said folded web at said first vertical endseal or said second vertical end seal, thereby producing a verticallyoriented pouch with a top, and a first compartment and a secondcompartment, wherein each compartment comprises an open end at said top;at least two feeders configured to feed a predetermined amount of afirst product or a second product into said compartments through saidopen ends; a sealer configured to seal said open ends to form a sealedmulti-compartment package. In another embodiment, one said feeder isconfigured to feed a first product into said first compartment andwherein another said feeder is configured to feed a second product intosaid second compartment, wherein said first product is different thansaid second product.

The method works on existing vertical or horizontal form, fill, and sealmachines requiring very little modification. The same metalized or clearlaminations used as materials in existing machines can also be used withthe invention. The above as well as additional features and advantagesof the present invention will become apparent in the following writtendetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a vertical form, fill, and seal machineaccording to one embodiment of the present invention.

FIG. 2 is a perspective view of a vertical form, fill, and seal machineaccording to one embodiment of the present invention.

FIG. 3 is a perspective view of a vertical form, fill, and seal machineaccording to one embodiment of the present invention.

FIG. 4 is a perspective view of a two-compartment bag in accordance withone embodiment of the present invention.

FIG. 5 is a perspective view of a horizontal form, fill and seal machineaccording to one embodiment of the present invention.

FIG. 6 is a perspective view of a two-compartment bag in accordance withone embodiment of the present invention.

DETAILED DESCRIPTION

One embodiment of the invention will now be described with reference toFIGS. 1-3. A vertical form, fill, seal packaging machine is seendiagrammatically in FIG. 1. This drawing is simplified and does not showthe cabinet and support structures that typically surround a machine,but it does clearly show how the machine works. Packaging film 110 isunwound from a roll 112 of film and passed through tensioners 114 thatkeep it taut. The material that is fed into the form, fill and sealmachine is typically a packaging film such as polypropylene, polyester,paper, polyolefin extrusions, adhesive laminates, and other suchmaterials, or from layered combinations of the above. For many foodproducts, where flavor retention is important, a metalized or barrierlayer will form the inner most layer.

The film then passes over a former 116, which directs the film into avertical tube around a product delivery cylinder 118. As the tube ispulled downward by drive belts 120 the vertical tube of film is sealedalong its length by a vertical sealer 122, forming a back seal 124. Inthe prior art, this sealed film tube is periodically sealed between twoheater bars and cut to make single-compartment, pillow-shaped packages.

One embodiment of the inventive machine utilizes two pairs of heatsealing jaws 126 and 128. The machine in FIG. 1 is depicted near the endof one cycle of a continuous process for producing two-compartmentpackages. The machine applies the pair of heat sealing jaws 126 againstthe tube to form a transverse seal. Part of this transverse seal acts asthe top seal 133 of the two-compartment package created by that cycle,and the other part of the transverse seal acts as the bottom seal 131 ofthe two-compartment package that will be made by the next cycle. Theheat seal jaws also cut the transverse seal at the dashed line thatseparates top seal 133 and bottom seal 131, releasing thetwo-compartment package. The heat seal jaws 126 are depicted in FIG. 1as not engaged with the film tube so that the result of the engagementof the heat seal jaws can be clearly shown.

In the embodiment shown in FIG. 1, distances L1 and L2 are depicted asapproximately equal. However, different lengths L1 and L2 are possible,depending on what types of products are packaged into each compartment.For example, if the bottom compartment is filled with unsalted potatochips and the top compartment is filled with salt, L2 will likely belarger than L1. However, if different components of a “trail mix” foodproduct are split between the two compartments, then L1 and L2 could beapproximately equal, or differ by, for example 10%. In any case, theoverall length of the two-component package will be L1+L2.

FIG. 2 depicts the machine very early in one cycle of creating atwo-component package. Heat seal bars 126 are engaged with the filmtube, and the two component package created by the previous cycle hasbeen cut at the transverse seal and is falling away from the machine.Also, food pieces have been dropped through product delivery cylinder118 and into the portion of the film tube above heat seal bars 126.

FIG. 3 depicts another step in the cycle of creating a two-componentpackage. Heat seal bars 126 are disengaged, heat seal bars 128 areengaged, and food pieces have been dropped through product deliverycylinder 118 and into the pocket of film tube above heat seal bars 128.The heat seal bars 128 create middle seal 134, which is a transverseseal across the film tube. After the food pieces have been dropped intothe film tube above the middle seal 134 created by the heat seal bars128 and the heat seal bars 128 have been disengaged from the film tube,the drive belts 120 advance the film tube downward a distance L1+L2(shown in FIG. 1). At this point, heat seal bars 126 create the top andbottom seals shown in FIG. 1, and cut the transverse seal to release thetwo component package. This represents the end of one cycle and thebeginning of another for creating a two component package of the presentinvention.

Another embodiment of the present invention is depicted in FIG. 5.Therein, a perspective view of an exemplary inventive horizontal form,fill and seal machine is depicted. It will be appreciated by one skilledin the art that some supporting structures, such as cabinets andconveyors, have been omitted to allow for better viewing of theinventive portions of the machine.

As shown in FIG. 5, a roll of packaging film 502 is unwound into asubstantially flat packaging film web 500. The packaging film web 500passes over forming neck 504 to form a folded packaging film web 505comprising a bottom fold 506. The folded packaging film web 505 may alsocomprise a gusset at the bottom, or at the bottom fold 506. Thepackaging film web may also comprise an optional reclose strip 510 suchas a tongue-in-groove or adhesive strip. The folded packaging film web505 advances through the horizontal form, fill, seal machine in acyclical manner similar to the cycle described above for the verticalform, fill, seal machine.

When the packaging machine has reached steady state, at least one pairof heat seal bars 518 engage the folded packaging film web 505 to form afirst vertical end seal 511 of the trailing package and a secondvertical end seal 508 of a leading package. A cutter (not shown) makes avertical cut in the folded packaging film web at the first vertical endseal of the trailing package and the second vertical end seal of theleading package to produce a vertically oriented, two-compartment pouchthat comprises a top and an open end at the top of each compartment ofthe pouch. Prior to the cutting step, a second set of heat seal bars 520engage the folded packaging film web to create a vertical middle seal507.

In an optional step, the open tops are pulled open further by, forexample, suction cups that engage the packaging film near the top andpull outward. The open topped two-compartment pouch or package thenproceeds to a filling step. Again, the equipment used to transport thefilm, pouches and packages through the horizontal form, fill and sealprocess has been omitted from FIG. 5 because it is known.

FIG. 5 depicts two separate hoppers 522 and 524 which are used to feed afirst product and a second product into first compartment 513 and secondcompartment 512, respectively. Although the feeding system shown in FIG.5 comprises two separate hoppers or feeders, it will be understood by askilled artisan that a single feeding tube can be used for bothcompartments with separate internal metering or delivery components usedto deliver two different products into the first compartment and secondcompartment.

In a final step, a top seal 516 (shown in FIG. 6) is created on thevertically oriented pouch which closes the open ends of the firstcompartment and second compartment. Equipment used to create the topseal can comprise one or more heat seal bars or other sealing meansknown in the art. The result is a two-compartment package comprising afilled first compartment 515 and a filled second compartment 514

One example of a two component package of the present invention isdepicted in perspective view in FIG. 4. As depicted in FIG. 4, in apreferred embodiment the middle seal 134 is narrower than top seal 133or bottom seal 131. This results in a middle seal that is more easilyrupturable than the top or bottom seal. Another exemplary embodiment ofa two-component package 600 of the present invention is depicted in FIG.6, which also comprises a middle seal 507 which has a lower sealstrength than the first end seal 511 or second end seal 508. When onecompartment of a two-component package shown in FIG. 4 or FIG. 6 issqueezed hard enough in the hands of a consumer, the middle seal willrupture before the top seal or bottom seal, converting thetwo-compartment package into a single compartment package.

The two-component package shown in FIG. 4 or 6 can be useful in manydifferent packaging applications. For a “trail mix” that comprisesrelatively dry components, such as pretzel pieces or cereal-basedpieces, mixed with relatively wet components, such as dried fruit pieces(for example, raisins or dried cranberries), initially packaging thesecomponents separate from one another prior to consumption improvesproduct quality considerably. When a moisture gradient exists betweentwo food pieces that are in the same headspace inside a package,moisture tends to migrate from the wet food pieces to the dry foodpieces. This can occur even with a relatively small difference inmoisture content, for example when cereal pieces have a moisture contentof about 2% and dried fruit pieces have a moisture content of about 10%.With the present invention, when good barrier film is used to create thetwo-component package, and when heat seal jaws are configured to createa hermetic seal for the middle seal, relatively dry components of atrail mix can be stored in one compartment, and relatively wetcomponents of the trail mix can be stored in the other compartment.These components can be mixed shortly before consumption by “popping”the middle seal and lightly shaking the package. The resulting trail mixwill have dry pieces that retain their crispiness, and wet componentsthat retain their chewy texture.

Another application of the two-component package is for unsalted orlightly salted (or unseasoned or lightly seasoned) snack chips. The termsnack chips includes all snack products sold and consumed in discretepieces, including sliced, fabricated and extruded products. In thisembodiment, unsalted or lightly salted snack chips are stored in onecompartment, and salt (or other seasonings, or salt and otherseasonings) is stored in the other compartment. If the consumer wants toconsume the snack chips without adding the salt or seasonings in theother compartment, the package can be opened at the top or bottom seal,as appropriate, to allow access to the compartment with the snack chipswithout rupturing the middle seal. The top or bottom seal is typicallyopened by pulling each side of the package apart at a location near thetop or bottom seal. If, however, the consumer wants to combine the saltor seasonings with the snack chips prior to consumption, the middle sealcan be “popped” and the package can be lightly shaken to distribute saltor seasoning over the outer surface of the snack chips.

With specific respect to salted snack chips or snack pieces, the presentinvention allows a practitioner to provide a reduced salt productwithout materially affecting the flavor of the product. When salt andsnack chips are packaged separately in the two-component package, andthe middle seal is ruptured to allow the salt to be distributed over theouter surface of the snack chips shortly before consumption, less saltis required because the salt will sit on the outer surface of the snackchip and will not quickly absorb into any oil found on the outer layerof the snack chip. When salt absorbs into the oil, it is masked fromproviding salty flavor inside the mouth. Topical application of salt tosnack chips immediately prior to consumption allows the consumer toimmediately taste the salt on the surface. Therefore, less salt isneeded to provide the same salty flavor impact.

The machine depicted in FIGS. 1-3 and 5 can be used to package twodifferent products in each compartment of the two-compartment package.In the vertical form, fill and seal embodiment, separate meteringequipment and delivery channels (not shown) are provided for eachproduct above product delivery tube 118. In the salt and snack chipapplication, the salt metering equipment and snack chip meteringequipment will alternate in feeding each product through the productdelivery tube 118.

In another embodiment, the apparatus of the present invention is used topackage the same product in all compartments of the multi-compartmentpackage. This embodiment can be used to provide several smaller servingsof food products which are individually packaged but attached to oneanother. The smaller, individual compartments can be used to store thefoods in each compartment under modified atmosphere (e.g. nitrogen) forlonger periods of time because each compartment can be exposed to theatmosphere, in particular the oxygen and moisture in the atmosphere, oneat a time when the food is ready to be consumed. In other words, for atwo-compartment package that contains salted potato chips in bothcompartments, a consumer can open one compartment at the top or bottomseal, thereby only exposing the potato chips in that compartment to theatmosphere. The potato chips in the unopened compartment may remainunder modified atmosphere and shielded from oxygen and moisture,allowing them to be fresher when the second compartment is opened at alater time. In a slightly modified version of this embodiment, thepackage of the present invention could deliver smaller servings of thesame food product, wherein each food product is seasoned with adifferent seasoning. For example, two different sets of potato chipshaving different types of seasoning could be stored separately in eachcompartment. These chips could then be mixed immediately prior toconsumption by rupturing the middle seal. This embodiment would reducemigration of seasoning between the different chip sets, providing asharper contrast between flavors when they are consumed together.

The present invention can be achieved with relatively inexpensivemodification of existing form, fill, and seal machinery. An additionalset of heat seal bars can be provided between the existing pair of heatseal bars and the bottom of the product delivery tube.

While the invention has been particularly shown and described withreference to a preferred embodiment, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.For example, shapes other than a circular shape as defined by a support350 can be used in the clamping mechanism.

What is claimed is:
 1. A method for making a multi-compartment package,said method comprising the steps of: forming a folded packaging film webfrom an unwinding roll of packaging film; forming a first vertical endseal on said folded packaging film web; forming a vertical middle sealon said folded packaging film web; forming a second vertical end seal onsaid folded packaging film web, wherein said vertical middle seal islocated between said first vertical end seal and said second verticalend seal; cutting said folded packaging film web at said first verticalend seal and said second vertical end seal to produce amulti-compartment, vertically oriented pouch having a top, as well as afirst compartment and a second compartment separated by said verticalmiddle seal, wherein each said compartment comprises an open mouth atthe top of the pouch; optionally opening said open mouths; filling eachsaid compartment through its open mouth with a predetermined amount of afirst product or a second product; forming a horizontal top seal on saidpouch which closes said open mouths and forms a sealed first compartmentbetween said first vertical end seal and said vertical middle seal, anda second sealed compartment between said second vertical end seal andsaid vertical middle seal.
 2. The method of claim 1 wherein said firstcompartment is filled with a first product and wherein said secondcompartment is filled with a second product which is different from saidfirst product.
 3. The method of claim 2 wherein said first productcomprises snack chips and wherein said second product comprises salt. 4.The method in claim 2 wherein said first product comprises a foodproduct with a moisture content of less than 4% by weight, and saidsecond product comprises a food product with a moisture content ofgreater than 5% by weight.
 5. The method in claim 2 wherein said firstproduct comprises a food product with a first seasoning, and said secondproduct comprises a food product with a second seasoning which isdifferent than said first seasoning.
 6. The method in claim 1 whereinsaid middle vertical seal is thinner than said first vertical end sealand said second vertical end seal.
 7. The method in claim 1 wherein saidmiddle vertical seal comprises a first seal strength, said firstvertical end seal comprises a second seal strength, said second verticalend seal comprises a third seal strength, and said horizontal top sealcomprises a fourth seal strength, wherein said first seal strength islower than said second seal strength, said third seal strength and saidfourth seal strength.
 8. A multi-compartment package made by the methodof claim
 1. 9. A horizontal form, fill, and seal machine comprising: aforming neck configured to convert an unwinding roll of packaging filminto a folded packaging film web; at least one pair of end heat sealbars configured to form a first vertical end seal and a second verticalend seal on said folded packaging film web; a pair of middle heat sealbars configured to form a vertical middle seal between said firstvertical end seal and said second vertical end seal; a cutter configuredto cut said folded web at said first vertical end seal or said secondvertical end seal, thereby producing a vertically oriented pouch with atop, and a first compartment and a second compartment, wherein eachcompartment comprises an open end at said top; at least two feedersconfigured to feed a predetermined amount of a first product or a secondproduct into said compartments through said open ends; a sealerconfigured to seal said open ends to form a sealed multi-compartmentpackage.
 10. The horizontal form, fill, and seal machine of claim 9wherein one said feeder is configured to feed a first product into saidfirst compartment and wherein another said feeder is configured to feeda second product into said second compartment, wherein said firstproduct is different than said second product.